Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/03—Powdery paints
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/03—Powdery paints
  • C09D5/033—Powdery paints characterised by the additives
  • C09D5/035—Coloring agents, e.g. pigments

Definitions

• the present invention relates to a method for the production of thermosetting powder paints, in particular for application by means of electrostatic plants.
• thermosetting powder paints have replaced solvent-based liquid thermosetting paints, resulting in considerable advantages in ecological terms owing to elimination of the solvent in which the solid components forming the coating paint were dissolved.
• the methods used envisage so-called fluid beds, inside which the powder paint is kept suspended inside a container, by means of a homogeneously distributed carrier gas (air), and the pre-heated metal part to be painted passes through this powder haze.
• the powder melts on the surface of the part and adheres to it.
• the powder undergoes a thermosetting reaction and becomes solid and fused with the part.
• Electrostatic spraying plants which imitate the abovementioned plants for performing liquid painting with solvent paints are widely used.
• These plants consist of a part similar to the abovementioned fluid bed, inside which the powder paint is kept mixed with a gas (air).
• This mixture is then transferred by means of pipes to a powder spray gun inside which an expelling thrust is imparted to this mixture by means of a Venturi tube.
• a magnetic field is generated between the tip of the spray gun and the part to be painted, this field having the effect that the particles, during their propelled movement, move along magnetic field lines.
• a more recent technology increases this movement of the particles under the influence of the magnetic field in that it creates a difference in potential of more than 100,000 Volts between the needle of the application nozzle and the part to be painted.
• a powder which is homogeneous in terms of its composition, specific weight and form, but non-homogeneous in terms of size, is thus obtained.
• the powder paint is suitable for coating the article in a homogeneous manner, except for the surplus of a small part of powder paint which, owing to its particle-size distribution, cannot be easily transferred onto the part.
• the particles which are too fine either do not receive sufficient energy to reach the part or along the path are attracted also by other elements and fall onto the bed of the spraying booth.
• part which is deposited onto the part is homogeneous and, after melting, forms a homogeneous film of paint, where the various pigments, to the naked eye, cannot be distinguished as a heterogeneous system, exactly in the manner of liquid paints.
• the mixture of the two powder paints, with a different specific weight and different particle-size curve, under the effect of the magnetic field is transferred onto the part with a composition different from that supplied, producing a shade different from that intended.
• the large-size particles normally used ranging from 20000 to 100000 nm (20 to 100 microns) and the binders normally used with a low molecular mobility, such as polyesters or epoxy polyesters or epoxides or acrylics which must impart functional properties to the powder paint, are such that the surface of the painted part will not have a homogeneous green colour, even if the transfer had been performed in a perfect manner, but will appear like a paint broken down into blue and yellow parts which are very small, but visible.
• the task of the present invention is to provide a system which embraces simultaneously different qualitative compositions, composed of conversion agents in which pigments pre-coated with aldehyde resins may be mixed so as to obtain powder paints with polyesters, polyesters cross-linked with epoxides, epoxides and acrylics, both in a glossy form and in a semi-glossy, matt, embossed, textured or metallized form.
• one object of the invention is to provide a method for producing a mixture which gives rise to a powder paint which behaves like the powder paint produced by pre-mixing of raw materials, extrusion and subsequent milling, without the typical abovementioned drawbacks of physical mixtures of powder paints.
• thermosetting powder paints in particular for application by means of electrostatic plants, characterized in that it comprises a system for cold and dry mixing pre-coated pigments, to be used in an amount of less than 30% with conversion agents in an amount greater than 70%, forming powder paints, chromatically non-pigmented or pigmented with a chromatic monopigment.
• the method according to the invention is designed in particular to formulate paints, in the form of a thermosetting coloured powder, intended to be applied by means of electrostatic plants.
• the system is constructed by preparing:
• the final powder paint will therefore be obtained by following the instructions for a formula where it is envisaged mixing in a selected conversion agent, chosen in accordance with the functional characteristics required of the final paint, a mixture of the pre-coated pigments, selected in accordance with the colorimetric,characteristics of each of them, so as to obtain the final colour required as per the formulation system.
• the ratios tested and required for the production of finished powder paints range from a minimum of 70% conversion agent up to a maximum of 30% pre-coated conversion agent. Minimum % Maximum % Pre-coated pigment mixture 5 30 Powder conversion agent 70 95
• a conversion agent not devoid of monochromatic pigment, but instead pigmented with a monochromatic pigment to be transformed in the final colour as per the procedure for a neutral conversion agent.
• thermosetting powder paint comprising not more than 30% by weight of at least one monochromatic pigment coated with at least one aldehyde and/or ketone resin, preferably from 5% to 30% by weight, and up to 95% by weight of conversion agent, preferably from 70% to 95% by weight, in which more than 90% of the particles of said at least one coated monochromatic pigment and of said conversion agent have a particle size of between 10000 and 40000 nm (10 and 40 microns), preferably between 15000 and 35000 nm (15 and 35 microns).
• said at least one coated monochromatic pigment and said conversion agent will have the "same" specific weight whereby this term is understood as implying a maximum variability of ⁇ 0.1 g/cc; in particular the specific weight of said at least one coated monochromatic pigment and the specific weight of said conversion agent will be between 1.3 and 1.7 g/cc.
• said at least one aldehyde and/or ketone resin has a mean molecular weight of between 800 and 2000 Da, preferably between 900 and 1400 and/or melting point of between 70° and 130°C, preferably between 90° and 120°C.
• aldehyde resin may be understood as meaning the condensation product of aliphatic aldehydes and urea
• ketone resin as meaning the condensation product of cyclohexanone or methylcyclohexanone, or the condensation product of cyclohexanone or methlcyclohexanone with urea or formaldehyde.
• Powder paint according to any one of the preceding claims characterized in that said at least one coated monochromatic pigment is formed by 80 to 20% by weight of said pigment and 80 to 20% by weight of said resin.
• the pigments pre-coated with aldehyde or ketone resins will be formulated taking into account the requirements for uniformity of specific weight.
• the constant specific weight level is obtained by correct metering of the components, resin, chromatic pigment, barium sulphate and calcium carbonate.
• the production will take place in the manner described in the already mentioned international patent application WO2006082603 , by means of mixing of this compound and subsequent extrusion and subsequent cryogenic milling with selection of the ground particles in accordance with a particle-size curve where 90% is in the range of 10000 to 40000 nm (10 to 40 microns); in particular, the monochromatic pigments coated with aldehyde or ketone resins, after the extrusion process are ground in cryogenic mills at temperatures below 10°C until the abovementioned particle-size curve is reached.
• the powder paint according to the present invention will contain from 2 to 4 different monochromatic pigments selected from among organic pigments and inorganic pigments.
• An example of a typical formula of the pre-coated pigment with a specific weight of about 1.5 g/cc is the following: Components in % aa bb cc Iron oxide pigment 30 Titanium oxide pigment 30 Organic pigment 10 Barium sulphate 00 00 34.5 Calcium carbonate 9 8 00 Coating resin 61 62 55.5 Specific weight of the formulated product (g/cc) 1.50 1.50 1.50
• the coated monochromatic pigment consists of 80 to 20% by weight of inorganic pigment, preferably 50 to 70%, even more preferably 55 to 65%, and 80 to 20% by weight of resin, preferably 30 to 50%, even more preferably 35 to 45%.
• the coated monochromatic pigment consists of 15 to 40% by weight of organic pigment, 45 to 75% by weight of resin, 1 to 20% by weight of mineral reinforcing filler and 0.1 to 10% by weight of dispersants; even more preferably 20 to 35% by weight of organic pigment, 50 to 70% by weight of resin, 5 to 15% by weight of mineral reinforcing filler and 1 to 7% by weight of dispersants.
• the mineral reinforcing filler is normally barium sulphate and/or calcium carbonate; the dispersants are normally selected from among sorbitan esters and epoxidized soybean oils, preferably epoxidized sorbitan ester.
• the powder conversion agents are proper powder paints, which lack solely the pigmenting part which confers the colouring; namely binders.
• the abovementioned term also includes the possibility of using a monochromatic conversion agent based on white titanium dioxide restricted to the very light final colours.
• the conversion agent is neutral or monochromatic.
• They must preferably contain a variable quantity of blanc fixe and calcium carbonate so that they have the same specific predefined specific weight for the tintometric system, according to the present invention.
• the conversion agents are produced using the normal systems for manufacturing powder paints by means of mixing of the components, followed by extrusion of the mixture and subsequent milling with selection of the particles, so that 90% of them lie within a particle-size curve of between 10000 and 40000 nm (10 and 40 microns).
• the final powdered paint will be obtained, therefore, following the instructions of a formula in which it is envisaged performing mixing with a conversion agent selected from among those mentioned above, chosen in accordance with the functional characteristics which the final paint must satisfy, hence a conversion agent with which a certain required quality has been associated.
• the conversion agent will be used in the minimum amount of 70% of the formulated product with a mixture of the pre-coated pigments, selected in accordance with the colorimetric characteristics of each of them, so as to obtain the final colour required as per the formulation system.
• the pre-coated pigments will be used in the maximum amount of 30% of the formulated product.
• a characteristic feature of the method according to the present invention consists in the fact that this mixture, applied to spray guns which use electrostatic systems for conveying the particles in the air as far as the part to be painted, remains homogeneous during the period of use, despite the presence of particles which have a heterogeneous chemical composition, but homogeneous physical structure, both as regards the dimensions, all being 90% within the range of 10000 to 40000 nm (10 to 40 microns) and as regards their mass; in fact, all the components have a specific weight with a variability factor within 0.1. g/cc.
• the particles all have a selected volume and different chemical compounds, but a similar specific weight and therefore very similar mass.
• the other characteristic feature of the method, according to the present invention consists in the fact of obtaining a uniform colour surface, as is normally obtained from a powder paint prepared using a process involving mixing, extrusion and milling of all the components.
• This process is used for all types of production batch, from a few kilos to various tonnes.
• the monochromatic pre-coated pigments are produced in low-cost batches, using the standard system for producing powder paints.
• the typical conversion agents of varying quality - which are powder paints devoid of monochromatic pigments - chosen for the system, are produced in large batches.
• the final powder paints are produced from the simple mixing of the conversion agents with the mixture of pre-coated pigments using highly flexible methods.
• the invention also relates to an electrostatic painting method comprising the use of the powder paint described above.

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• Chemical & Material Sciences (AREA)
• Life Sciences & Earth Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Wood Science & Technology (AREA)
• Organic Chemistry (AREA)
• Paints Or Removers (AREA)
• Processes Of Treating Macromolecular Substances (AREA)
• Application Of Or Painting With Fluid Materials (AREA)

Priority Applications (2)

Applications Claiming Priority (2)

Publications (2)

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• 2005
  • 2005-07-08 IT IT001303A patent/ITMI20051303A1/it unknown
  • 2005-09-19 JP JP2008520065A patent/JP2009508973A/ja active Pending
  • 2005-09-19 PL PL05794423T patent/PL1902104T3/pl unknown
  • 2005-09-19 ES ES05794423T patent/ES2322176T3/es active Active
  • 2005-09-19 US US11/993,712 patent/US8329781B2/en not_active Expired - Fee Related
  • 2005-09-19 PT PT05794423T patent/PT1902104E/pt unknown
  • 2005-09-19 DE DE602005012741T patent/DE602005012741D1/de active Active
  • 2005-09-19 CA CA2614681A patent/CA2614681C/en not_active Expired - Fee Related
  • 2005-09-19 RS RSP-2009/0223A patent/RS50844B/sr unknown
  • 2005-09-19 DK DK05794423T patent/DK1902104T3/da active
  • 2005-09-19 EP EP05794423A patent/EP1902104B1/en active Active
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  • 2005-09-19 WO PCT/IT2005/000536 patent/WO2007007359A1/en active Application Filing
  • 2005-09-19 AT AT05794423T patent/ATE422526T1/de active
  • 2005-09-19 SI SI200530667T patent/SI1902104T1/sl unknown
• 2008
  • 2008-01-11 KR KR1020087000955A patent/KR101263778B1/ko not_active IP Right Cessation
• 2009
  • 2009-04-24 HR HR20090242T patent/HRP20090242T1/xx unknown

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